The provided document is a service and repair manual for the Hyster A290 (P2.0) Forklift, specifically focusing on its AC Motor Controller. This manual is designed for trained and experienced technicians, providing general guidelines for maintenance and service.

The AC Motor Controller is a solid-state device that manages the operation of the forklift's traction motor, brake, and hydraulic system. It receives inputs from the control handle via serial communication and direct inputs from other switches, such as the key switch and the control handle arm position switch, depending on the specific model. The controller's primary function is to regulate the speed of the traction motor and the operation of the hydraulic lift pump motor. It employs a sophisticated microprocessor to control its logic and operation, eliminating the need for forward and reverse contactors. This design incorporates numerous programmable features, including maximum speed, acceleration rate, neutral braking, and braking current limit, ensuring reliable operation. The controller also features comprehensive diagnostic and setup capabilities, which are accessible through a Curtis handset. It's important to note that the Curtis controller does not contain user-serviceable parts, and any attempt to open, repair, or modify it will void the warranty and may damage the unit.

For usage, the forklift's operation is managed through the AC Motor Controller, which translates inputs from the control handle into precise motor and hydraulic system movements. The controller's software includes self-diagnostics, which are accessed using a 1311 Curtis programmer handset. This handset is a crucial tool for programming, testing, and diagnosing the traction motor controller. It features a menu navigation key, a data increase/decrease key, and three bookmark keys to control all programmer functions. The handset's display is a 7-line, 128 × 64 pixel LCD screen that can show both text and graphics, visible in most lighting conditions and adjustable via the programmer setup menu. The programmer operates on a menu-driven interface, with submenus accessed by the menu navigation key. When connected to the motor controller, the handset uploads all current controller information, allowing technicians to view and modify parameters. This upload also enables the programmer to generate menu items for display. The data increase/decrease key is used to adjust various parameter settings, while bookmark keys allow users to quickly return to frequently accessed menu items. These bookmarks are retained in the programmer's memory, but are cleared if the programmer is unplugged or power to the controller is interrupted.

Maintenance and repair procedures emphasize safety precautions. Before any maintenance or repair on electric lift trucks, the battery connector must be disconnected. For internal combustion lift trucks, the battery ground cable must be disconnected. Heavy parts should not be lifted manually; a lifting mechanism should always be used. Safety glasses are mandatory. When working on the AC Motor Controller, a critical safety step is discharging the capacitors, which can retain an electrical charge even after the battery is disconnected. This is done by connecting a 100-ohm, 25-watt resistor across the controller's B+ and B- terminals using insulated jumper wires. A screwdriver must never be used to discharge the traction motor controller. Proper blocking of the wheels is required to prevent the unit from rolling or falling. The work area must be kept clean and orderly, and correct tools, in good condition, should be used. Only Hyster-approved parts, meeting or exceeding original equipment manufacturer specifications, should be used for repairs. All nuts, bolts, snap rings, and other fastening devices must be removed before using force to remove parts. A "DO NOT OPERATE" tag must be fastened to the unit's controls during repairs or if the unit needs repairs.

The programming of the controller using the 1311 handset involves several steps. First, the key switch is turned OFF, the battery disconnected, and the drive unit compartment cover removed. After discharging the capacitors, the handset is connected to the 4-pin Molex™ connector on the traction motor controller. The battery is then reconnected, and the key switch turned ON. Technicians can then select the "PROGRAM" menu on the handset, use the menu navigation key to scroll to the desired function, and press the right arrow to enter the function for modification. The data increase/decrease key is used to change the function setting. It is crucial to never adjust function settings outside the recommended range for the specific truck model, as program changes can significantly affect lift truck performance and operation. Operators must be informed of any changes. The "FUNCTIONS" menu allows copying data between motor controllers or resetting data to original settings. The "INFORMATION" menu displays controller details like model number, serial number, manufacturing date, and software version. The "PROGRAMMER SETUP" menu offers customization options.

The controller also features a Status LED, visible through a window on the label, which displays fault codes. During normal operation without faults, this LED flashes steadily like a heartbeat. Fault codes can appear intermittently during truck use, often due to power loss from the battery. Turning the key switch OFF and then ON again usually clears these codes. If codes persist, the lift truck requires service. Persistent intermittent faults necessitate checking for loose cable connections at the battery and controller, as well as verifying battery cell voltage and state of charge. Fault codes are detailed in the manual, providing display messages, descriptions, potential causes (e.g., Controller Overcurrent, Current Sensor Fault, Precharge Failed, Controller Severe Under/Overtemp, Severe Undervoltage/Overvoltage, 5V Supply Failure, Digital Out Overcurrent, Motor Temp Hot Cutback/Sensor Fault, Coil Driver Open/Short, Encoder Fault, Motor Open, Main Contactor Welded/Did Not Close, Throttle Wiper High), and troubleshooting steps. These steps typically involve checking parameters via the monitor menu, inspecting wiring and connections, verifying component conditions (e.g., motor insulation, fuses, contactor tips, coils, sensors), and restarting the truck. If troubleshooting fails to resolve the issue, replacing the controller is often indicated. The display (BDI)/hourmeter provides a continuous sequence of hourmeter readings, battery state of charge, and fault messages. Minimum reset voltage for the BDI is 25.2 volts (open cell), with a specific gravity of approximately 1.250 per cell.

Hyster P2.0 - Page 2

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